manifold JAGUAR X308 1998 2.G Manual PDF

In
stallation


6.
Re
move the exhaust manifold to EGR valve tube.
Remove and discard the ex

haust manifold to EGR valve
tube gasket.

1. NOTE:
Install a new exhaust manifold to EGR valve tube
gasket.
Loosely install the exhaust manifold to EGR valve tube.

2. NOTE:
Install a new exhaust manifold to EGR valve tube
gasket.
Install the exhaust manifold to EGR valve tube retaining bolts.
Tigh te
n to 21 Nm.
3. Tighten the exhaust manifold to EGR valve tube retaining bolts.
Tighte
n to 21 Nm.

Intake Air Distribution and Filtering -
Torque Specificat
ions


Comp

onent
Nm
Thr
o
ttle intake elbow to intake manifold
18
-
24
Thro
tt
le body to throttle intake elbow
18
-
24
Left-hand support
bracket to
th
rottle intake elbow
16
-
20
Right-hand support
bracket to
throttle intake elbow
16
-
20
B
l
anking plate to throttle intake elbow
18
-
24
Inta
k
e manifold to engine
20
-
22
Supe
rcharger
drive belt idler pulley bolt
34
-
46
Supercharger
drive belt te
nsioner to alternator mounting bracket bolt
39
-
51
Supercharger
to eng
ine bolts
18
-
24
Charge air cooler in
let assembly to charge ai
r cooler bolts
18
-
24
Supercharger
outlet duct to supercharger bolts9-1
1
Charge air cooler in
let assembly to superchar
ger ou
tlet duct bolts
18-
24
Charge air cool
er to charge
air cooler adaptor
11
-
13
B
y
-pass valve to throttle intake elbow
8-
1
2

P a
rts List
It
e
m
Par
t
Number
De
scr
iption
1—Inta
k
e Manifold
2—E
l
ectronic Throttle
3—Inta
k
e Elbow
Throttl
e
and Manifold Assemblies

2.2. Cruise
3. 3. Mechanica l
guard
4. 4. Fixed idle
5. 5. Redundancy
6. 6. Full authority
7. 7. Engine shut-down
Normal mode occurs when the EC M uses the mechanical and monitoring arrangem ent of the throttle valve to control throttle
opening. The ECM does not permit driver demand to be exceeded but it can be restricted to allow for such features as
stability / traction control, or engine power limitation.
The ECM determines engine idle speed by controlling the throttle valve motor to vary the blade angle between the non-
adjustable preset limits of the mechanic al guard and the throttle valve motor.
Cruise mode is engaged as a result of the ECM calculating and controlling the required throttle valve opening via the
vacuum system. When the driver releases the throttle pedal, the input shaft disengages from the mechanical guard or the
vacuum actuator pulls the guard away from th e throttle valve. The throttle pedal will feel light should it be pushed again to
accelerate (pressing the pedal further will re-engage the input shaft with the mechanical guard and restore normal feel).
The ECM utilizes sensors to monitor the relative positions of the mechanical guard and throttle valve and adjusts them to
maintain the set cruise speed.
Mechanical guard mode permits full mechanical operation of the throttle if the ECM detects that a problem has been
encountered with the throttle valve position sensor, dc motor, associated harnesses / connecto rs or the ECM.
Fixed idle mode occurs when any two of the three sensors (two input shaft sensors and the mechanical guard sensor) fail.
The ECM will assume values which represent a blade angl e of approximately 2,5° and 1200 rpm (unloaded) maximum
engine speed.
Redundancy mode occurs when any one of the three sensors (two input shaft sensors and the mechanical guard sensor)
fails. The operational pair will be deemed to be safe to co ntinue without intervention, but cruise will be inhibited.
Full authority mode is invoked when a mech anical guard failure occurs which indicates that the guard is stuck fully open.
The red warning lamp will be lit and road speed will be li mited to 120 kph.
Engine shut-down mode will occur followin g multiple failures, such as mechanical guard mode following full authority mode
(or vice versa) or the throttle blade sticks.
Intake Elbow

The intake elbow directs the metered airflow from the electronic throttle to the intake manifold. Stub pipes on both sides of

the
intake elbow provide connections for vacuum actuators and are also used to redirect emissions into the engine.
On the right-hand side of the elbow a la rge diameter pipe connects to the brake servo. The smaller pipe provides a vacuum
feed to the fuel rail pressure regulator and throttle cruise control system. On the le ft-hand side of the elbow the front pipe
supplies vacuum control for the evaporative emissions system valves.
Emissions from the engine part load breather (bank 2) and pu rged fuel vapor from the EVAP valve are drawn via a common
T piece into the left-hand side of the intake elbow. Re-cir culated exhaust gas enters the intake elbow via the EGR valve
which is mounted directly on the rear of the elbow : where the EGR system is not used, a blanking plate is fitted.
The fuel system, throttle and emission control system s are described more fully in the relevant sections.
Intake Manifold

Filtered air from the vehicle's intake ducting is metered by th e electronic throttle and distributed to the two cylinder banks
via an integral intake manifold.
The intake manifold is manufactured in plastic with integral plastic fuel rails and metal-thread inserts; the very smooth
internal surfaces give excellent air flow.
Individual ducts lead off a central chamber to the inlet valves of each cylinder.
Silicon-rubber gaskets, loca ted in channels in the intake manifold, seal th e joints between the ducts and the cylinder heads.
Engine Ventilation

The e
ngine is ventilated through two brea
thers; a part-load breather and a full-load breather, one on each camshaft cover.
The outlet hose for the part-load breather is connected between the bank 2 camshaft cover and the intake elbow. The full-
load outlet hose is connected from the bank 1 camshaft cover to the intake duct between the MAF sensor assembly and the
throttle body.
Constructed in plastic, the hoses incorporate O-ring seal s and quick-release connectors; refer to Section 303-01.
I
ntake Air Distribution and Filtering - Supercharged Vehicles
Ai
r is supplied to the supercharger via an
intake cleaner/duct, throttle assembly and intake elbow which are similar to those
used for normally aspirated engines. The su percharger delivers pressurized air to two separate charge air cooler units, each
unit being mounted on the cy linder bank which it supplies. Pr essurized cooled air is fed from the charge air coolers directly
into each inlet port.

11
.
Remove intake manifold.
1. Remove ten bolts.
2. Remove intake manifold

12
.
Discard eight seals from intake manifold ports.

13
.
Remove throttle intake elbow from intake manifold.
1. Remove seven bolts.
2. Remove elbow.
3. Remove seal.
14. Where necessary, remove blanki ng plate from intake elbow.
Re
move bolts.
Di

scard gasket.
Cle

an all mating faces.

In
stallation
15.
Cle
an manifold and mating faces on cylinder heads.
1. Where necessary, install blanking plate to intake elbow.
Inst al
l new gasket.
Inst
al
l bolts (18-24Nm).

2. Inst al
l intake elbow to intake manifold.
1. Install new seal.
2. Install seven bolts.
3. Install new seals to the eight intake manifold ports. Ensure the
seals are fully seated.

4. Inst al
l intake manifold.
1. Install ten bolts.
5. Connect fuel feed hose to fuel rail feed pipe. Ensure hose is
fully installed.
6. Connect fuel return hose to fuel rail return pipe. Ensure hose is
fully installed.

7. Con n
ect electrical connectors to fuel injectors.
8. Install left-hand support brac ket to intake elbow and re-
connect pipework.
1. Install bolt.

Evaporative E
missions - Evaporative Emissions
Description an
d Operation

To reduce the emission of fuel vapour, th e fuel tank is vented to atmosphere through activated charcoal adsorption canister
(s) which collects the fuel droplets. The ch arcoal is periodically purged of fuel when the EVAP Canister Purge Valve opens
the vapour line between the canister(s) and the air intake induct ion elbow. This action allows manifold depression to draw
air through the canister atmospheric vent, taking up the deposited fuel from the charcoal adsorber and burning the resulting
fuel vapour in the engine.
The EVAP Canister Purge Valve is controlled by the engine management system ECM. Purging is carried out in accordance
with the engine management fu eling strategy (see below).
The fuel tank vapour outlet is via a removeable flange assemb ly on the top surface of the tank. The vapour storage canister
or canisters are fitted on the underside of the vehicle below the rear seats.
There are three variants of the evaporativ e system. All systems use the charcoal adsorber storage canisters and purge valve
and operate as described above. The specific features of each system are described below. The evaporative systems are
designated as :
sin g
le canister system
ru
nn
ing loss system
ru
nn
ing loss with On-board Re-fueling Vapour Recovery (ORVR) system
EVAP Canister Purge Valve

Ite
m
Par
t
Number
De
scr
iption
1—EVAP canister purge v
alve
2—Valve s
olenoid connector
3—Vapour outlet to indu
ction elbow
4—Vapour
inlet from canister(s)
5—Vacuum contro
l pi
pe from induction elbow
6—Vacuum contro
l pi
pe to vapour pressure control va
lve - applicable to single canister systems only
7—Vacuum
control connection to EVAP valve

Thi s
system uses a single charcoal canister with a pressure
control valve between the canister and the fuel tank vapour
outlet. A vacuum control pipe is connecte d from the engine intake induction elbow to the pressure control valve. The vapour
outlet from the fuel tank is taken via a safety rollover valve fitted to the re moveable flange at the top of the tank.
With the engine stopped, the pressure control valve is closed, maintaining a slight positive pre ssure in the tank : any further
increase in pressure causes the valve to open and release vapour to the canister.
When the engine is running, manifold depr ession (via the vacuum control pipe) holds the pressure control valve open. Air is
drawn into the tank to maintain atmospheric pressure as fuel is used and vapourised fuel is deposited in the charcoal
canister.
Canister purge operation is as described in Evaporative Emissions Control.
It e
m
Par
t
Number
De
scr
iption
1—Evaporative flan
ge assembly
2—Vapour outlet rol
lover valve
3—Tank vapour outlet pipe
4—Breather
pipe
5—Pressure control valve
6—Induct
ion vacuum control pipe
7—Charcoal can
i
ster
8—Canister vapour outlet pipe
9—EVAP canister purge v
a
lve
10—Vacuu
m
control sign
al from induction
11—EVAP ca
nister purge valve outlet
12—Canist
er vent
to atmosphere
Single Ca
nister System

E
lectronic Engine Controls - Ca
mshaft Position (CMP) Sensor
Re
moval and Installation
Remov

al
1.
Disc
onnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Remove engine covers ; refer to 12.30.06.
3. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
De-pressurize fuel system; refer to 19.50.02.

4. R
emove coolant expansion tank fixings and reposition tank for
access.

5. R
emove bolts securing fuel fe
ed pipe to inlet manifold.

6. Di
sconnect fuel feed pipe from inlet manifold and pull pipe
assembly clear.
Di
scard O-ring.
Inst

all suitable blanking plugs.
7. Disconnect CMP sensor connector.
De
press tang on connector to release, tools are not
necessary.